CHOOSING CORE MATERIALS FOR AEROSPACE APPLICATIONS

Transcription

1 CHOOSING CORE MATERIALS FOR AEROSPACE APPLICATIONS

2 GENERAL PLASTICS MANUFACTURING CO. General Plastics supplies aerospace and defense manufacturers with build-to-print flexible foam products and aerospace-grade rigid foam core materials. WHERE GREAT IDEAS TAKE SHAPE Established in 1941, General Plastics has been supplying the global aerospace industry for over 60 years. Among its capabilities: Sheet stock, machined parts and complex laminates Finished parts/build-to-print On-site R&D, chemists and scale-up engineers On-site analytical/testing capability ISO 9001:2008/AS9100C, NQA-1, MIL-I A quality systems ITAR compliant

3 KEY TAKE-AWAYS COMPOSITE MATERIALS Overview Industry Trends FST/OSU Testing Process Requirements FR-3800 FST FOAM Features and Benefits Applications

4 COMPOSITE MATERIAL Benefits of Composite Core Materials Reduced weight Environmental impact Increased design capabilities

5 Composites % of Airframe Weight INDUSTRY TRENDS 45 Years of Composites Evolution (Commercial Transports) Entry Into Service Source:

6 PASSENGER JET OPERATING EXPENSES Fuel 35-50% Source: U.S. Energy Information Administration U.S. Gulf Coast Kerosene -Type Jet Fuel Spot Price FOB

7 TRENDS IN THE AEROSPACE INDUSTRY: FAA specifications Weight considerations Drive down costs Other requirements

8 FST/OSU SPECIFICATION Fire Smoke density Toxicity Ohio State University -Heat Release Method FAA FST/OSU requirements: 65/65/200

9 FST/OSU SPECIFICATION Fire

10 FST/OSU SPECIFICATION Smoke density

11 FST-OSU SPECIFICATION Toxicity

12 FST-OSU SPECIFICATION Ohio State University -Heat Release Method

13 FST-OSU SPECIFICATION Fire Smoke density Toxicity Ohio State University -Heat Release Method FAA FST/OSU requirements: 65/65/200

14 FAR AND OEM AEROSPACE SPECIFICATIONS

15 HOW TO CHOOSE AEROSPACE MATERIALS Things to Consider: Processing limitations associated with materials Strength-to-weight ratio Cost Performance Safety Requirements

16 LAST-A-FOAM FR-3800 FST PU-based core material Halogen-free Passes FST OSU 65/65/200 specification Physical properties congruent with other PUbased core materials o 18, 20 pcf densities meet BMS

17 AEROSPACE MATERIALS CORE MATERIALS COMPARISON LAST-A-FOAM FR-3806 FST PESU PMI PEI End-Grain Balsa Nominal Density (lb/ft3) C/S (psi) C/M (psi) NA Shear Strength (psi) Shear Modulus (psi) Tensile Strength (psi) NA Tensile Modulus (psi) NA NA Smoke Density Pass Pass Fail Pass Fail Total HR Pass Pass Fail Pass Fail Peak HR Pass Pass Fail Pass Fail Tg (F) >350

18 Smoke Density (200 Ds Max) Heat Release (65/65 Max) Heat Release FR-3804 Peak HRR Total HR Lab A Lab B Lab C Lab D Lab E Test Facility Smoke Density FR Lab A Lab B Lab C Lab D Lab E (General Plastics) Test Facility

19 Smoke Density (200 Ds Max) Heat Release (65/65 Max) Heat Release FR-3804 Peak HRR Total HR Lab A Lab B Lab C Lab D Lab E Test Facility Smoke Density FR Lab A Lab B Lab C Lab D Lab E (General Plastics) Test Facility

20 FR-3800 FST FOAM OFFERS Passes Fire/Smoke/Toxicity (FST) requirements High strength-to-weight ratio from crosslinked structure Meets OSU 65/65 heat release standards Alternative to thermoplastics and honeycomb in FST applications Withstands process temperatures up to 310 F Bonds well with composite skins Resistant to most chemicals and solvents Will not support fungal growth No edge-closing or filling needed Range of densities: 3-40 pcf

21 OPTIONS FOR USE

22 THERMOFORMABLE Easy processing Drape / mold forming Can form all densities

23 SANDWICH PANEL LAYUPS Process using standard vacuum bag layup techniques Processing temperatures above 275 o F

24 POUR IN PLACE PARTS High levels of detail Complex shapes without machining Smooth or textured skin

25 HIGH MACHINABILITY Smooth surface finish Minimal dust

26 Conclusion COMPOSITE MATERIALS Weight reduction Enhanced Performance Overall cost reduction FST/OSU FAR flammability specs Materials testing FR-3800 FST FOAM High strength to weight ratio Low cost material Versatile processing

27 Q & A G. Joel Meyer, Ph.D. Chemistry Laboratory Manager General Plastics Manufacturing Co. joel_meyer@generalplastics.com